Jeep XJ. Manual — part 805
TRANSFER CASE NV-231
TABLE OF CONTENTS
page
page
TRANSFER CASE NV-231
VEHICLE SPEED SENSOR
TRANSFER CASE NV-231
DISASSEMBLY
Position transfer case on shallow drain pan.
Remove drain plug and drain lubricant remaining in
case.
REAR RETAINER AND OIL PUMP
(1) Remove the speedometer adapter.
(2) Spread band clamp which holds output shaft
boot to the output shaft slinger, or output shaft
damper, with a suitable awl, or equivalent.
(3) Remove output shaft boot from slinger, or out-
put shaft damper, and output shaft.
(4) If the vehicle is equipped with an automatic
transmission, remove the output shaft rear slinger
using Puller MD-998056-A (Fig. 1).
(5) If the vehicle is equipped with a manual trans-
mission, use Screws 8421 and the puller yoke and
forcing screw from a bolt-grip puller set, such as
those used to remove steering wheels and harmonic
balancers, to remove the transfer case output shaft
damper.
(6) Use a suitable pry tool, or a slide hammer
mounted screw, to remove the seal from the rear
retainer (Fig. 2).
(7) Remove the rear output bearing I.D. retaining
ring (Fig. 3).
(8) Remove the bolts holding the rear retainer to
the rear case half.
Fig. 1 Rear Slinger Removal
1 - TRANSFER CASE
2 - SPECIAL TOOL MD-998056-A
3 - SLINGER
Fig. 2 Rear Retainer Seal
1 - REAR RETAINER
2 - OUTPUT SHAFT SEAL
Fig. 3 Output Shaft Rear Bearing Retaining Ring
1 - SNAP-RING PLIERS
2 - REAR BEARING I.D. RETAINING RING
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TRANSFER CASE NV-231
XJ
2001 JEEP CHEROKEE
(9) Tap rear retainer with rawhide or rubber mal-
let to loosen sealer bead.
(10) Remove rear retainer from rear case half (Fig.
4).
(11) Remove snap-ring holding oil pump in position
on output shaft.
(12) Disengage oil pickup tube from oil pump and
remove oil pump assembly. Remove oil pump by tilt-
ing the edge of the oil pump from under the edge of
the rear case half and sliding the pump (Fig. 5).
(13) Remove pick-up tube o-ring from oil pump
(Fig. 6), if necessary. Do not disassemble the oil
pump, it is not serviceable.
YOKE AND RANGE LEVER
(1) Remove transfer case indicator switch.
(2) Remove front yoke nut as follows:
(a) Move range lever to 4L position.
(b) Then remove nut with socket and impact
wrench (Fig. 7).
(3) Remove yoke. If yoke is difficult to remove by
hand, remove it with bearing splitter, or with stan-
dard two jaw puller (Fig. 8). Be sure puller tool is
positioned on yoke and not on slinger as slinger will
be damaged.
(4) Remove seal washer from front output shaft.
Discard washer as it should not be reused.
(5) Remove nut and washer that attach range
lever to sector shaft. Then move sector to neutral
position and remove range lever from shaft (Fig. 9).
Fig. 4 Rear Retainer Removal
1 - MAINSHAFT
2 - REAR RETAINER
Fig. 5 Oil Pump Removal
1 - OIL PUMP
Fig. 6 Pick-up Tube O-ring Location
1 - OIL PUMP
2 - O-RING
Fig. 7 Yoke Nut Removal
1 - IMPACT WRENCH
2 - SOCKET
3 - YOKE
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TRANSFER CASE NV-231
21s - 43
TRANSFER CASE NV-231 (Continued)
2001 JEEP CHEROKEE
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Support transfer case so rear case is facing
upward.
(2) Remove bolts holding front case to rear case.
The case alignment bolts require flat washers (Fig.
10).
(3) Loosen rear case with flat blade screwdriver to
break sealer bead. Insert pry tool blade only into
notches provided at each end of case (Fig. 11).
(4) Remove rear case from front case.
(5) Remove oil pickup tube from rear case (Fig.
12).
(6) Remove mode fork spring (Fig. 13).
Fig. 8 Yoke Removal
1 - PULLER TOOL
2 - YOKE
Fig. 9 Range Lever Removal
1 - RANGE LEVER
2 - SECTOR SHAFT
Fig. 10 Rear Case Alignment Bolt Locations
1 - DOWEL BOLT AND WASHER (2)
2 - CASE BOLT (5)
3 - SPLINE HEAD BOLT (1)
Fig. 11 Loosening Rear Case
1 - REAR CASE
2 - PRY TOOL (IN CASE SLOT)
3 - FRONT CASE
21s - 44
TRANSFER CASE NV-231
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TRANSFER CASE NV-231 (Continued)
2001 JEEP CHEROKEE
(7) Pull front output shaft upward and out of front
output shaft bearing (Fig. 14).
(8) Remove front output shaft and chain.
SHIFT FORKS AND MAINSHAFT
(1) Remove detent plug, O-ring, detent spring and
detent plunger (Fig. 15).
(2) Remove mainshaft from mode sleeve and input
gear pilot bearing.
Fig. 12 Oil Pickup Tube Removal
1 - CONNECTING HOSE
2 - PICKUP SCREEN
3 - PICKUP TUBE
Fig. 13 Mode Fork Spring Removal
1 - MODE SPRING
Fig. 14 Remove Front Output Shaft And Chain
1 - DRIVE CHAIN
2 - FRONT OUTPUT SHAFT
3 - SHAFT FRONT BEARING
Fig. 15 Detent Plug, Spring And Plunger Removal
1 - POPPET
2 - SPRING
3 - SCREW
4 - POPPET BORE (IN CASE)
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TRANSFER CASE NV-231
21s - 45
TRANSFER CASE NV-231 (Continued)
2001 JEEP CHEROKEE
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